Composite interlocking pavers

ABSTRACT

A composite paver system comprising two distinct types of interlocking pavers, both being formed from a mixture of sawdust and polymers. One type of paver has a groove around the entire periphery, and a plurality of interlocking members are provided to fit into the grooves between adjoining pavers to secure them together. The other type of paver comprises a plurality of tiles all of which are notched at each corner, and at least one interlocking member that fit into the notches at the corners of adjoining tiles. The interlocking members are screwed to the corners to secure the tiles together as one unitary paver. Using both formats an economical composite patio or deck surface can be built at one fourth the weight of conventional cement pavers, at a lower cost (using a wood mitre saw for trimming rather than a diamond cut saw), and yet with increased integrity. Moreover, the reduced thickness and weight of the pavers eases installation by reducing the excavation needed as well as the carrying weight of the pavers thereto.

CROSS-REFERENCE TO RELATED APPLICATION(S)

[0001] The present application derives priority from U.S. Provisional Patent Application No. 60/444,071 filed Jan. 30, 2003.

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] The present invention relates to paver systems for decks, patios, walk paths, and other open on grade surfaces and, more particularly, to a composite paver system for with interlocking feature to simplify assembly, ensure a more uniform deck appearance, and to prevent shift and/or roll over time.

[0004] 2. Description of the Background

[0005] To improve their aesthetics, decks and patios are often surfaced by tiles and/or pavers. Such pavers provide durability, protection and performance despite harsh weather conditions. Currently, there are a variety of pavers available to give a variety of textured finishes and appearances. Moreover, pavers can be cut and intermixed to yield striping, banding and paving patterns having unique colors, sizes and finishes. The typical steps for laying a paver surface are as follows:

[0006] 1. Demarcate perimeter

[0007] 2. Drive stakes in around perimeter.

[0008] 3. Excavate down to assure that there is room for base layers upon which the pavers will lie, and create a level but sloping surface (for drainage).

[0009] 4. Lay gravel about 4 inches thick and tamp it down.

[0010] 5. Fill the bed with about 1½ inches of stone dust and level it.

[0011] 6. Lay the pavers over the stone dust, tamping each paver.

[0012] 7. Spread another layer of stone dust over the paver and sweep into cracks between the pavers and along the edge.

[0013] 8. Spray water over the pavers to secure them in the stone dust. The stone dust will harden.

[0014] Unfortunately, existing pavers are relatively thick (3-4″) and require a great deal of excavation down about eight inches to assure that there is room for base layers upon which the pavers lie. Moreover, existing pavers are made from cement or stone and are very heavy. This not only presents problems and undue expense in shipping and distribution, but it also creates functional problems. The installation of a large paver job becomes a physically challenging affair. Moreover, the weight of the pavers can cause them to settle over time. It would be greatly advantageous to provide a light-weight alternative without sacrificing functionality or aesthetics.

[0015] There are a number of lighter-weight composite materials used in fabricating decking. One of the first composites introduced was Trex®, a combination of furniture sawdust mixed with polymers. Trex® requires virtually no maintenance, comes with a ten year warranty and does not need to be sealed. Newer composite lumbers include: TimberTech®, SmartDeck™ and Dreamworks™. The low maintenance aspects of these composite wood panels has helped them to gain widespread acceptance in recent years for above-ground applications such as decks.

[0016] However, they have not been adapted for use as pavers because they are one-fourth the weight of cement, lack vertical stability, and are much more prone to wind and weather.

[0017] It would be greatly advantageous to design an economical composite paver system with interlocking feature that provides stability, and which automatically spaces the pavers to give an aesthetically pleasing deck structure, at one fourth the weight of conventional cement pavers, without compromising integrity.

SUMMARY OF THE INVENTION

[0018] It is, therefore, an object of the present invention to provide a light weight composite paver system with interlocking feature that provides vertical stability, and automatically spaces the pavers to give an aesthetically pleasing deck structure.

[0019] It is another object to provide a composite paver of 1-1.5″ thickness that eases installation by reducing excavation, and by lightening the carrying load.

[0020] It is another object to provide a composite paver which allows the use of a wood mitre saw rater than a diamond cut saw for trimming.

[0021] It is another object to provide a scalable composite paver design with interlocking feature that gives the ability to fasten the edges, and which prevents shifting or roll over time, thereby increasing the structural integrity of the finished surface.

[0022] It is still another object to provide a scalable composite paver design which facilitates easy replacement of damaged pavers.

[0023] According to the present invention, the above-described and other objects are accomplished by providing a composite paver system comprised of two distinct types of interlocking pavers, both being formed from a mixture of sawdust and plastic.

[0024] One type of paver has a groove around the entire periphery, and a plurality of interlocking members are provided to fit into the grooves between adjoining pavers.

[0025] The other type of paver comprises a plurality of tiles all of which are notched at each corner, and at least one interlocking member that fit into the notches at the corners of adjoining tiles. The interlocking members are screwed to the corners to secure the tiles together as one unitary paver.

[0026] Using both formats an economical composite patio or deck surface can be built at one fourth the weight of conventional cement pavers, without compromising integrity.

BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Other objects, features, and advantages of the present invention will become more apparent from the following detailed description of the preferred embodiments and certain modifications thereof when taken together with the accompanying drawings in which:

[0028]FIG. 1 is a side perspective view of a composite paver 2 according to a first embodiment.

[0029]FIG. 2 is a front perspective view of two composite large paver 2A & 2B with interlocking members 6.

[0030]FIG. 3 is a top perspective view of a plurality of composite large paver 2 assembled together.

[0031]FIG. 4 is a side perspective view of a composite paver 4 according to an alternative embodiment.

[0032]FIG. 5 is a front perspective view of two composite large paver 4A & 4B with interlocking members 8.

[0033]FIG. 6 is a top perspective view of a completed patio surface formed from composite large paver 2, 4 in accordance with the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0034] In all of the succeeding paver embodiments the pavers are formed by combining recycled plastic and sawdust (approximately 50 percent recycled wood, like wood fiber from sawdust and used wooden pallet, and 50 percent recycled plastic materials, from plastic grocery bags and industrial stretch film). These materials are mixed together, and then extruded into boards. The boards are then cut into pavers as described. The pavers are defect free, low maintenance products, and once installed only occasional washing is necessary. They resist rot and decay, and under usual conditions should last a lifetime.

[0035]FIG. 1 is a side perspective view of a composite paver 2 according to a first embodiment. Here, the paver 2 is formed as a rectangular brick-like form of 4″×8″ dimensions with a ½″ groove extending around its entire periphery (approximately ⅓ of the way from the bottom of the paver 2). Each paver 2 is approximately 1-1.5″ thick. The combination of reduced mass and thickness greatly reduces weight and eases installation. Moreover, the reduced thickness reduces the necessary excavation. The pavers 3 may be compression-molded in this configuration or extruded and machined.

[0036]FIG. 2 is a front perspective view of two composite large paver 2A & 2B as in FIG. 1 with interlocking members 6. Each interlocking member 6 is a flat member having a thickness that conforms to the grooves 21 in pavers 2 (for a friction fit). The interlocking members are approximately 1.0″ wide and 4″ long, such that when inserted sidelong between two pavers 2A & 2B they automatically space the pavers approximately 0.125″ apart from each other. Generally, two interlocking members 6 will be used alongside of each paver 2, and one along each end. The interlocking members 6 provide vertical and lateral stability, and the automatic spacing gives an aesthetically pleasing appearance. It is envisioned that the foregoing paver 2 design (with interlocking members 6) will be provided in 4″ to 12″ square and rectangular sizes, although larger sizes are possible.

[0037]FIG. 3 is a top perspective view of a plurality of composite large pavers 2 assembled together. The interlocking feature gives the ability to fasten the edges around the patio, and this prevents shifting or roll over time. If a paver 6 is ever damaged the composite design facilitates easy replacement.

[0038] In addition to the discrete pavers of FIGS. 1-3, larger pavers may be constructed either by integral molding or from component parts.

[0039]FIG. 4 is a side perspective view of a composite paver 4 according to an alternative embodiment. The composite paver 4 comprises four (or any other number) of discrete tiles 42 secured together with corner locks 44 that are screwed to the corners of adjoining tiles 42 via screws 46. Each discrete tile 42 is notched at all four corners to seat the corner locks 44, and corner locks 44 are screwed onto the corners of adjoining tiles 40 via stainless steel screws 46 to collectively form a larger paver 4.

[0040]FIG. 5 is a close-up perspective view of two composite tiles 42 with seated corner locks 44 screwed onto the corners via stainless steel screws 46. These pavers 4 are provided in square and rectangular sizes ranging from 12″×12″ to 24″×24″.

[0041] Given an array of pavers 2, 4 of differing dimensions, it becomes a simple task to compile an entire patio surface.

[0042]FIG. 6 is a top perspective view of a completed patio surface formed from an array of composite large paver 2, 4 in accordance with the present invention. It is readily apparent that the composite paver system uniformly spaces individual pavers to give an aesthetically pleasing deck structure. In addition, the interlocking feature provides vertical stability and greatly increases the structural integrity of the finished deck or patio surface, especially around the edges where it prevents shifting or roll over. In addition, the interlocking feature allows easy replacement if a paver is ever damaged. Moreover, the reduced 1-1.5″ thickness eases installation by reducing excavation and carrying weight, and a wood mitre saw can be used for trimming rather than a diamond cut saw.

[0043] Having now fully set forth the preferred embodiments and certain modifications of the concept underlying the present invention, various other embodiments as well as certain variations and modifications of the embodiments herein shown and described will obviously occur to those skilled in the art upon becoming familiar with said underlying concept. It is to be understood, therefore, that the invention may be practiced otherwise than as specifically set forth in the appended claims. 

I claim:
 1. A composite paver system, comprising: a plurality of solid composite members each being formed from a mixture of sawdust and plastic and having a groove around the entire periphery; a plurality of interlocking members that fit into the grooves between adjoining composite members.
 2. A composite paver system, comprising: a plurality of solid composite members each being formed from a mixture of sawdust and plastic and being notched at each corner; a plurality of interlocking members that fit into the notches at the corners of adjoining composite members to secure them together. 